Decorative wall hanging heater

ABSTRACT

A wall hanging incorporating a heater is characterized by a low temperature thermostatically controlled heating panel being aesthetically concealed behind a decorative surface, and being configured to be hung on an ordinary wall. The device includes a safety shut-off switch activated by excessive temperature build-up, alarm systems to deter theft, and a wall mounting bracket which permits rapid and level mounting of the wall hanging.

CROSS REFERENCES TO RELATED APPLICATIONS

This is a divisional application of Ser. No. 07/034,279, which issued asU.S. Pat. No. 4,817,906 which is a continuation-in-part of Applicant'scopending application for Combined Decorative Picture and Room HeatingDevice, Ser. No. 579,113, filed Feb. 10, 1984, now abandoned.

BACKGROUND OF THE INVENTION

This invention relates to a wall hanging including a heat source andmore particularly to a wall hanging with a heating panel having athermostatic control, a safety cut-off switch, and simple alarm means todeter theft.

Heat transfer by radiation and convention have long been used as meansfor transferring energy in situations where the object to be heated is arelatively small room, and the temperature differential between the roomand the outside is relatively low.

Prior devices for heating a small space, such as a room in a residenceor a hotel room, include baseboard radiators, radiant heaters attachedto or placed in ceilings, radiant heaters in floors and forced airsystems. These prior art heating devices are inherently inefficient andeven in relatively warm regions, such as Southern California, requireabout six watts per square foot of floor surface area to provideadequate heating.

There are also radiant wall heating panels. Such heating panelsgenerally operate at relatively lower temperatures, seldom exceeding 150degrees Fahrenheit, and may further include a decorative type coating sothat the panel may be mounted on a wall and still be harmonious with thesurroundings. An example of such a heating panel is disclosed in U.S.Pat. No. 3,453,413. Heating panels of this general nature are generallyconstructed of components especially fabricated for this purpose andhave no means for controlling the heat output.

U.S. Pat. No. 3,612,823 to the subject inventor discloses a portabledecorative heating device formed as a panel to be hung on a wall toprovide heat by both radiation and convection.

SUMMARY OF THE INVENTION

The present invention is an improved device to heat a room primarily byconvection currents from a low temperature heating panel that isdecoratively concealed in a wall hanging. The present invention providesa simple construction of the heating panel and additionally providingfor a safety cut-off switch to prevent heat build-up, a thermostaticcontrol means to regulate the heat output of the invention, and a novelbracket for mounting the frame to a wall.

The invention is designed for use in residences, offices and incommercial settings such as motel rooms, and in other environments wherehigh-output heaters are not practical. The present invention may furtherprovide simple alarm means that will alert the owner of its removal froma wall.

In the preferred embodiment of the invention, the decorative covercomprises a front panel, preferably of 20 gauge paint lock steel,surrounded by a wooden frame. Two panels are positioned behind the frontpanel, and are comprised of a material that exhibits thermal conductingand electrical insulating properties. A panel heater is positionedbehind these layers and generally comprises of a layer of graphitesaturated fabric, which receives electrical current from buses on eitherend of the heater. The insulating layers and the heater are affixed toone another by two sided adhesive tape strips which are placed on thestructural surfaces.

In order to protect against excessive heat build-up and potential firehazard, the panel heater has a bi-thermal cutoff switch whichdisconnects the source of electricity from the wall hanging should overheating occur. Additionally, a thermostat is provided to variablycontrol the heat output of the wall hanging.

The invention includes a hanging mechanism that provides a convenientsturdy means for securing the wall hanging to a vertical surface. Thisvertical surface may be a wall or a shelf lip or nearly any otherdesired support surface. The hanging mechanism consists generally ofthree elements, an angle bracket, a means for leveling the bracket, anda means for minutely or vernier adjusting the orientation of the wallhanging. The angled bracket is formed having a plurality of slotstherein, through which screws secure the bracket to the desired mountingsurface. A portion of the bracket extends outward and perpendicularlyfrom the vertical portion to provide a ledge or surface upon which theframe of the wall hanging can rest upon. The ledge portion includes aslot that receives a screw or any convenient protrusion, such as awooden dowel or peg extending from the frame of the wall hanging, toprevent the wall hanging from sliding off the ledge formed by theoutwardly extending or ledge portion of the bracket. This arrangementallows for a reliable but quick engagement and/or disengagement means ofthe item from the wall. The shape of said slots permits the fasteners toengage wall studs or the like to provide a stable mounting and allowslateral adjustment of the wall hanging relative to the bracket orfasteners. Furthermore, because of the rigidity of the bracket, thebracket enables the mounting of such items to any type of verticalsurface capable of supporting the bracket, including to merely a shelflip.

Also fixedly mounted to said bracket is a bubble level means fordetermining the horizontal level of the mounting bracket's wall hangingsurface. This enables the quick leveling of the bracket without the needor inconvenience of using auxillary leveling means which often times arecumbersome to work with in conjunction with small brackets such as thepresent one.

Furthermore, with the vernier adjustment mechanism the orientation ofthe wall hanging can be rapidly changed without having to disengage afixedly mounted bracket from a set position. In addition, suchadjustments can be made in minute quantized increments. This is adistinct advantage over the prior art, wherein such adjustments weremade by the hit or miss process of bracket bending or total removal andreattachment of the bracket to the wall. For example, if the item isplaced near a non-plumbed structure, such as a door jam, the horizontallevel of the picture may be altered without having to remove the wallbracket so that the vertical edge of the wall hanging would not seem soincongruent with said non-plumbed structure.

The invention may include systems to deter the unwanted removal of thewall hanging from the wall. One alarm device is completely concealed,and involves a two connector switch located in the wall receptacle whichis closed to complete a circuit when the wall hanging is unplugged fromthe wall receptacle. The closed circuit can then be used to trigger analarm, or signaling device, indicating that the wall hanging has beenremoved. A second alarm system is located on the wall above the wallhanging and contains two connectors separated by a movable connectorwhich is held in a closed position by a magnet located above the wallhanging. When the wall hanging is removed from the wall, the absence ofthe magnetic force allows the movable contact to break the circuitbetween the two connectors, thereby activating an alarm system. A thirdalarm system produces a radio frequency signal in the building wiring ifthe heater is unplugged from its wall receptacle. A monitoring stationreceives the alarm signal. The alarm system may also include an audiblealarm attached directly to the wall hanging for producing a loud noisein the event of unauthorized removal of the wall hanging from the wall.

Thus, in summary, the present invention provides means by which heat canbe controllably delivered to a room from a concealed and aestheticallyacceptable wall hanging means for attaching the wall hanging to a wall,and further provides safety features to eliminate the risk ofoverheating, and several alarm systems to deter unwanted removal.

BRIEF DESCRIPTION OF THE DRAWINGS

These as well as other features of the present invention will becomemore apparent upon reference to the drawings wherein:

FIG. 1 is a perspective view of the present invention as it would beplaced on the wall;

FIG. 2 is an exploded view of the wall hanging of FIG. 1 taken alongline 2--2, illustrating the major components of the wall hanging;

FIG. 3 is a view of the backside of the wall hanging showing the backclosure panel and the junction box illustrating the structure of theelectrical circuitry of the invention;

FIG. 4 is a partial cutaway view of the heater showing the peripheraledge comprising a seal, the bus bar, and the graphite-filled centersection;

FIG. 5 is a schematic drawing of the circuits for the thermostat, theindicator light, and the bi-metal thermal cutoff switch;

FIG. 6 is a schematic diagram of the structure and circuitry utilized inone alarm system having a switch for the alarm in the wall receptacle,activated by removal of the plug of the wall hanging;

FIG. 7 is a partial perspective view of the backside of the wall hangingshowing the mounting bracket and a second alarm system;

FIG. 8 is a schematic drawing of a second alarm system illustrating themanner in which the alarm circuit is activated by the removal of themagnetic force; and

FIG. 9 illustrates an alarm switch that may be used in the second alarmsystem.

FIG. 10 is a bottom perspective of the mounting bracket displaying themounting bracket, fixedly mounted level means and vernier adjustmentmechanism.

FIG. 11 illustrates the manner in which the painting may be required todeviate from the horizontal after the mounting bracket is secured to thewall.

FIG. 12 is a perspective view of the portable wall heater stand.

FIG. 13 is a frontal view of the bracket with the vernier adjustingmechanism in operation.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The invention comprises, as shown in FIGS. 1 through 13, a wall hanging10 including as major components: a panel assembly, designated generallyby the numeral 12, which is fabricated or painted with any desiredportrait or scene, an anti-theft device 100 and a hanging mechanism ordevice, designated generally by the numeral 200.

Referring to FIGS. 2 and 3, the frame 14 may be any conventional woodenor molded plastic structure. The panel assembly 12 comprises a planarpaint panel 16 upon which an aesthetic scene or painting is located. Thepaint panel 16 is preferably formed of 20 gauge paint lock steel, or anequivalent material, and includes a flange 18 extending from an edge 21thereof, through which a number of screws 20, typically fourteen toeighteen, secure the panel 12 into the frame 14. The paint panel 16 hasupon it a quantity of paint or other decorative coloring 22. It will berecognized that the thicknesses shown in this exploded view are somewhatexaggerated for clarity; in particular, the thickness of the painting 22or coloring or decorative material is shown in exaggerated proportion.

An insulating layer 24 is secured by means of a plurality of strips of atwo-sided adhesive tape 26 to the backside of the paint panel 16. Thematerial of the layer 24 is an electrical insulator but is a thermalconductor. A preferred material is a film known as NOMEX (trademark)manufacturated by E.I. DuPont. Likewise, another layer 27 of NOMEX, orother comparable electrically insulating material, is secured by meansof a plurality of adhesive strips 28 to the layer 24 to provideadditional electrical insulation. A panel heater 32 is secured bysuitable means such as a plurality of two-sided adhesive strips 30 tothe backside of the layer 27.

Secured to the backside of the heater 32 is a bi-metal thermal cutoffswitch 48, the function of which will be described hereinafter. Next, alayer 50 of insulating material, preferably glass fiber insulatingmaterial, covers the heater 32, and finally a back panel 52 having aflange 54 extending around it is positioned adjacent the layer 50. Theback panel 52 is secured by suitable means such as a plurality of screws56 to the frame 14. A conductive bracket 58 electrically connects thepaint panel 16 with the back panel 52. This bracket 58 may be simplyflat or it may preferably be an L-shaped bracket which will engage anedge of the back panel 52 and secure it to the front panel 16 by meansof the screws 20 and 56. The bracket 58 permits the use of a singleground connection (not shown) to electrically ground the externalportions of the wall hanging 10 to avoid risks of electric shock topersons and to prevent fires. The panel heater 32 heats the front panel14 to a temperature of about 150 degrees Fahrenheit while the insulatinglayers prevent the temperature of the rear panel 52 from exceeding about100 degrees Fahrenheit, well within safety limits.

Reference is made now to FIGS. 2 and 3 to explain in further detail thestructure in electrical operation of the invention. FIG. 3 is a view ofthe backside of the wall hanging 10 showing the back panel 52 and ajunction box 60. The wall hanging 10 includes a heater which providesconvection circulated heat to a room in which it is hung. Electricity isprovided to the wall hanging by inserting a plug 62 into any convenientelectrical outlet. A power cord 64 carries electrical current into thejunction box 60 from which a first conductor 66 supplies current to abimetal thermal cutoff switch 48 which is an absolute cutoff ofelectricity to the wall hanging 10 should overheating occur. The flowelectric current is controlled by a thermostat 68 which includes acontrol knob 70 having a shaft 71 extending through the frame 14 so thatthe thermostat is accessible from outside the frame 14. A light 72 isprovided to indicate when the wall hanging 10 is operating to provideheat. Electrical current is provided to a pair of bus bar 40 and 42 bymeans of electrical conductors 41 and 43, respectively, connected to apair of connectors 44 and 46, respectively. The heater 32 may beconveniently designed to draw power proportional to the cross sectionalarea, generally 0.5 watts per square inch.

FIG. 4 illustrates the bus bar 40 and the connector 42 being adjacentthe graphite saturated fabric 38 along an edge 67 of the heater 32 toprovide a uniform and controllable panel heating effect. Heaters of thistype are manufactured by Canada Thermal Film, Ltd. of Concord, Ontario,Canada and are sold under the trademark THERMAL FILM.

FIG. 5 schematically depicts the circuitry described above. The plug 62plugs into a conventional electrical outlet. The flow of electricalcurrent to the rest of the circuitry is controlled by the bi-metalthermal cutoff switch 48. The heater 32 may be conveniently representedto include an electrically resistant heating element 71. The light 72 isconnected in parallel with the heating element 71 and glows wheneverelectrical current passes through the heating element 71. The bi-metalthermal cutoff switch 48 is preferably a standard commercially availablethermal cutoff switch that is preset to cut off at a desiredtemperature, such as 210 degrees Fahrenheit, which is satisfactory inmost applications. The junction box 60 includes a plurality of vents 80,82 and 84 in FIG. 3 which allow air flow upwardly through the junctionbox 60 allow the bi-metal sensor 74 to respond to the air temperature inthe room.

FIG. 6 shows a wall receptacle 86 in a conventional junction box 88. Thewall receptacle 86 has electrical connectors 89, 91 to provideelectricity to an outlet. The connector 91 is a ground connectorincluding a switch comprising contacts 90 and 94 which, when the groundconnector of the plug 62 is inserted into the wall receptacle 86, close,forming a circuit between a ground 92 and the contact 94, which isconnected to a central alarm 96. The plug 62 and the wall receptacle 86are most useful in motels and hotels to prevent theft of the wallhanging 10. The contact 94 may be connected to a conventional alarm 96through a conduit 98. The alarm 96 is inoperative when grounded; butwhen the ground is broken, the alarm 96 sounds or gives a signal, thusindicating that the plug 62 had been pulled, suggesting the possibilitythat the wall hanging 10 was being stolen.

The wall hanging 10 may include a second theft alarm unit 100, shown inFIG. 8. The alarm unit 100 is mounted to the bracket 201 connected by apair of electrical connectors 102 and 104 to a wall-mounted device 106,such as a bell, light, horn or other warning device. Mounted under thetop edge of the frame 14 is a bar magnet 110. Inside the alarm unit 100are a pair of magnetically permeable connectors 112 and 114 and amovable contact 116 which is also a magnetically permeable element. Theconnector 104 is electrically connected to a contact 118. When the wallhanging 10 is moved into position, for example on a wall, the magneticflux from the bar magnet 110 passes through the connectors 112 and 114and the movable contact 116 then closes, thus forming a completeelectrical circuit between electrical conduits 102 and 104. When thecircuit is closed, the warning device 106 is inoperative. When the wallhanging 10 is moved, the circuit is opened to actuate the warning device106. Likewise, disconnecting the circuit through lines 102 and 104, suchas by removal of the alarm unit 100 would break the circuit and indicatethe likelihood of a theft.

As shown in FIG. 9, the alarm unit 100 may include a switch 120 that isopen when the wall hanging 10 with the magnet 110 attached thereto ispositioned on the bracket 201. A movable contact 122 is spring-biased tobe closed when the wall hanging is not in position. The movable contact122 is magnetically permeable so that having the magnet 110 near causesthe contact to move toward the magnet, away from a fixed contact 124 toopen the circuit and deactivate the alarm.

Referring to FIGS. 7 and 10, the hanging mechanism or device, designatedgenerally by the numeral 200, comprises an elongate bracket, designatedgenerally by the numeral 201, having an L-shaped cross-sectionalconfiguration. One leg portion 205 of the bracket 201 includes aplurality of elongate slots 202, 204 and 206 through which fastenerssuch as bolts, screws or nails 208, 210 and 212, respectively, mayextend. The other leg portion 207 of the bracket 201, includes a centralslot 214 sized to receive the head of a mounting screw 216 which issecured to the undersurface of the frame 14 of the wall hanging 10. Thebracket 201 is mounted in a level position using a bubble level 218,shown in FIG. 7, rigidly affixed to the bracket 201 to usually indicatelevel positioning.

The bracket 201 provides a very firm and sturdy shelf-like mount for thewall hanging 10 and permits rapid level mounting of the wall hanging 10without the need of auxiliary leveling means such as a carpenter'slevel. The bracket 201 also permits a reasonable amount of lateraladjustment to position the wall hanging 10 upon a wall. The slots 202,204, 206 permit selection of locations of the corresponding fasteners208, 210, 212 so that they may be securely attached to the internalstuds of the wall. A screw 216 affixed to the frame 14 passes throughthe slot 214 to retain the frame 14 upon the bracket 201. The slot 214permits adjustment of the position of the wall hanging relative to thebracket 201 so that the bracket 201 may be optimally positioned tosupport the wall hanging 10 and to permit the wall hanging 10 to beplaced in a desired location on the wall.

Advantageously, the bracket 201 may be provided with vernier adjustmentmeans 219a and 219b to permit small incremental changes in the levelingof wall hanging 10 after the mounting bracket 201 is fixedly mounted tothe wall.

As best shown in FIGS. 10 through 13 the vernier means for minutelyadjusting the level of the wall hanging 10 comprises a pair of screws219a and 219b, threadingly inserted into mating tapped holes 234 and 236formed adjacent opposite ends of the bracket 201. As will becomeapparent, the unique incorporation of the screws 219a and 219b allowsfor the subsequent manual adjustment of the axial extension of thelength of the screws 219a and 219b from the top surface of the legportion 207 of the bracket whereby, upon placement of the frame 14 uponthe bracket 201, a minor amount of canting of the frame 14 relative thebracket 201 is achieved without having the need to dismount the wallbracket 201 in order to obtain desired orientation of the wall hanging10 upon the wall through a trial and error process.

In operation, the approximate or desired height or location for the wallhanging 10 upon the wall is selected and marked. The mounting bracket201 is manually placed at the desired height, flush with the verticalsurface to which it is to be attached and the bolt or first attachmentmeans 208 is placed through slot 202 and loosely tightened to initiallyengage the vertical surface. The other end of the bracket 201, may bemanually held at this time and is free to pivot about the first looselyattached end. The bracket 201 may then leveled to the horizontal byviewing the bubble level 218 and vertically adjusting the free end ofthe bracket 201 until the entire bracket 201 is disposed in a levelorientation. The other plurality of fasteners or attachment means 210and 212 may then inserted through their respective slots 204 and 206 andtightened to fixedly mount the said bracket 201 to the wall in such alevel horizontal position. The wall hanging 10 may then be positionedupon the bracket 201 in the manner previously described to mount thehanging 10 in a desired location.

If the wall hanging 10 need only remain in the fixed horizontal levelorientation, no further adjustments need be made. However, there aretimes when the wall hanging 10 is placed next to a door frame or otherpermanent structure 238 which is not correctly plummed. Morespecifically, referring to FIG. 11, the placement of the wall hanging 10near a non-plummed door frame 238 may result in an aestheticallyunpleasing arrangement. To adjust the picture's orientation, even afterthe mounting bracket 201 is rigidly affixed to the wall, rapid vernieradjustment may be provided by threadingly inserting or withdrawing oneor both of the vernier adjusting screws 219a and 219b after the bracket201 is fixedly mounted on the wall. To adjust the wall hanging 10, thehanging 10 is lifted vertically to raise the frame 14 and its attachedmounting screw 216 out of the slot 214 and remove the same from thebracket 201. The adjustment screw 219a or 219b, depending on which sideor end of bracket 201 is desired to be raised, is axially extended orretracted the desired amount to raise or lower the respective end of thewall hanging 10. The wall hanging 10 is then replaced on the mountingbracket 201 so that the mounting screw 216 is reinserted through centralslot 214 whereby the undersurface of the frame 14 contacts and issupported upon the heads of the adjustment screws 219a and 219b. Anylateral adjustment can be made by sliding the frame 14 relative thebracket 201 while retaining the mounting screw 216 engagement within thecentral slot 214. Note that mounting screw 216 may be any protrusion, awooden dowl or peg for example, so that the frame 14 won't slide off thebracket 201. As such, the use of the vernier adjustment, screws 219a and219b provides for advantages not available to other devices, since themounting bracket 201, once affixed to the wall, need not be removed toenable minor adjustment.

Referring now to FIG. 12, a free standing mounting device 239, for usein areas where wall space is unavailable or for use when portability ofthe wall hanger heating device 10 is desired, is depicted. The baseconsists of two U-shaped pipe elements 240 and 242 disposed in a commonplane and rigidly attached to one another via a rectangular base plate244. Centrally extending perpendicularly and upwardly from the baseplate 244 is a first tubular member 246 which is fixedly mounted at oneend to a standard pipe coupling 248 attached to the base 244 and isprovided on its opposite end with a standard bell coupling/bell-reducer250. A second tubular member 254, having an outside diameter sized to besmaller than the inside diameter of the first tubular member 246 istelescopingly positioned within the first tubular member 246. A thumbscrew 252 extending radially through the bell-reducer 250 isadditionally provided to permit or restrict relative axial position ofthe first and second tubular members. A pair of mounting brackets 201may be attached by conventional fastening means such as screws orweldments to the top end of the tubular member 254 to provide a mountingmeans for the wall hanging 10.

In operation, the particular room or location for the free standingmounting device 239 is selected. The stand 239 may then be placed atthat location. By firmly grasping the second tubular member 254 with onehand, the thumb screw or retaining means 252 may be disengaged by theoperator so that the said second tubular member can freely telescope outfrom or into the length of first tubular member 246 to the desiredheight. The retaining means 252 may then be tightened to contact thesecond tubular member 254 and retain the same at such desired height.The wall hanging 10 is then placed upon the stand 239 by resting theframe 14 on the mounting bracket 201 so that the mounting screw 216 isinserted through central slot 214 of the bracket 201. The level of thewall hanging 10 may then be adjusted as earlier discussed by varying theinsertion or extension of adjusting screws 219a and 219b.

The wall hanging 10 provides many advantages which are not found in theprior art. These advantages include such features as easy and securemounting to the wall, theft detection, and, most importantly, abeautiful and decorative way to provide heat to a living area.

The wall hanging 10 has low radiation losses and supplies heat to theair in a room by convective flow of air over the panel 12. The panel 12heats air adjacent thereto, causing the air to rise and be replaced bycooler air beneath the frame 12. It has been found that by providing aslittle as 2 watts per square foot of floor space, so that for example,in an average room in Southern California, adequate heating forreasonable comfort can be provided. Air flowing past the panel is heatedabout 20 degrees in passing from the lower edge to the upper edge. Theefficiency increases as the difference between panel 14 temperature andambient temperature increases. The invention has a high efficiencybecause it does not waste heat at the ceiling level, providingsubstantially uniform temperature throughout a room. Recommended powerrequirements are about 6 watts per square foot for other types ofheaters.

It will be recognized that while the circuitry shown is generally thatfor a 120 volt system, the heaters can be and are designed for use witha 240 volt system as well. Having described a preferred embodiment ofthe invention, various modifications will now become apparent from thespecification and the drawings which fall within the scope of theappended claims.

What is claimed is:
 1. A combination decorative wall hanging and panel heater, comprising:a front panel surface formed as a sheet having decorative coloring and a flange formed to extend generally at right angles from the edges thereof; a frame formed to surround the front panel and for securement to the flange; a layer of material having heat conducting and electrical insulating properties juxtaposed to the front panel; a second layer of material having dielectric properties juxtaposed to the first layer of material; a heater element including a layer of graphite saturated fabric having a pair of busses positioned along a pair of opposite edges of the layer of graphite saturated fabric; means for supplying electrical current to the busses for application to the heating element; a thermal cut-off switch connected to the heater and in series with the means for supplying electrical current; thermostat means for variably regulating the heat output of the panel heater; a backing panel having a flange adapted to be secured to the frame; an electrically conductive bracket adapted to be attached between the front panel and the backing panel; a junction box having a plurality of vents for allowing air circulation therethrough attached to the backside of the heater for housing the thermostatic means; bracket means for supporting the wall hanging to a vertical surface; and alarm means for providing a warning whenever the frame is removed from the vertical surface; said bracket means comprising a mounting plate formed to be secured to a vertical surface; a supporting plate integrally formed with and extending perpendicularly from said mounting plate sized to capture a portion of said frame; a level means located on said mounting plate for indicating the relationship of said supporting plate to the horizontal; and a pair of vernier adjusting means located on said supporting plate for adjusting the level of said frame relative said supporting plate after said frame is captured by said supporting plate.
 2. The device of claim 1 wherein said level means comprises a bubble level.
 3. The device of claim 2 wherein said vernier adjusting means comprises a pair of threaded fasteners extending through said supporting plate and positioned to support a portion of said frame and cant said frame relative said supporting plate. 